Machine and a plant for dyeing textile materials

ABSTRACT

Machine for dyeing textile materials, characterized in that it comprises a stationary structure ( 1 ) with a surface ( 100 ) for supporting or parking the materials already treated or to be treated, said materials being disposed upon said surface at corresponding predetermined positions, in that it comprises a surface ( 101 ) with a plurality of tanks ( 4 ) to be fed with a dye bath, and in that it comprises means ( 60 ) for removing and handling the materials between said supporting or parking surface ( 100 ) and said tanks ( 4 ), the said means ( 60 ) being associated with a programmable unit (UE).

[0001] More particularly, the present invention makes it possible tooptimise the procedures for the preparation of the so-called “dyeingbaths” and to rationalize as well the automation of the subsequentsteps, that is, the use of the dyeing baths, while resultingparticularly useful for dyeing reels of yarns. This result has beenachieved, according to the invention, by providing a machine and a planthaving the characteristics disclosed in the independent claims. Furthercharacteristics being set forth in the dependent claims.

[0002] The advantages of the present invention will be best understoodby anyone skilled in the art from a reading of the following descriptionin conjunction with the attached drawings given as a practicalexemplification of the invention, but not to be considered in alimitative sense, wherein:

[0003]FIGS. 1 and 2 show a machine for dyeing reels of textile yarnsaccording to the invention, in side and plan views, respectively;

[0004]FIGS. 3 and 4 show a machine for dyeing reels of textile yarnsaccording to a further embodiment of the invention, in side and planviews, respectively;

[0005]FIG. 5 shows a detail of the dyeing tank;

[0006]FIG. 6 shows a plan view of the tank in FIG. 5;

[0007]FIGS. 7 and 8 show a lid for closing the tank of FIG. 5, in sideand plan views, respectively;

[0008]FIG. 9 shows a detail of a reel-holder;

[0009]FIG. 10 shows schematically the stage of engaging a reel-holder;

[0010]FIG. 11 shows schematically the stage of engaging a lid;

[0011]FIG. 12 shows schematically a plant according to the invention,with a dye-cooking or metering machine (MD), a plurality of machines fordyeing reels of a type shown in FIGS. 3 and 4, and a dissolution unit(D) acting as an interface;

[0012]FIG. 13 is a plant view of the plant shown in FIG. 12;

[0013]FIGS. 14 and 15 show schematically the said machine (MD) in sideand plan views, respectively;

[0014]FIGS. 16 and 17A show schematically the said dissolution unit, infront and side views, respectively;

[0015]FIG. 17B is an enlarged detail of the drawing in FIG. 17A;

[0016]FIG. 18 is an enlarged detail of the upper part of the dissolutionunit;

[0017]FIG. 19 illustrates the steps for metering the products needed tomake a dyeing bath;

[0018]FIG. 20 illustrates the steps for dissolving and launching theproducts; and

[0019]FIG. 21 is a simplified block diagram of the operations controlsystem.

[0020] Reduced to its basic structure, and reference being made to thefigures and the attached drawings, a machine (MT) for dyeing reels ofyarns according to the invention comprises a structure (1) with ahorizontal surface (100) for supporting or parking the reels (2) alreadytreated or to be treated. Each reel (2) is housed in a correspondingreel-holder (3) and each reel-holder takes a corresponding predeterminedposition onto said surface (100). The said structure (1) furthercomprises a surface (101) acting as a support for a plurality of tanks(4) to be fed with a dyeing bath (being either the same or different forall the tanks, according to the production being programmed) and intowhich the reels are inserted according to procedures to be describedlater on.

[0021] Also associated to the surface (101) of the tanks (4) are asubstantially cylindrical container with vertical axis having lids (40)stacked therein intended to sealingly closing the tanks (4), and one ormore service spaces (110) possibly housing therein one or morecentrifuges or other suitable devices for taking out residual water orovens for centrifuging and hot drying the material gradually removedfrom the tanks (4).

[0022] The said structure (1) has two upper longitudinal guides (102)with a bridge (5) driven into a sliding movement there along by acorresponding electric motor (MX). The said bridge (5) makes up aguiding element for a carriage (6) associated with an electric motor(MY) allowing it to me moved along the same bridge. The guides (102) andthe bridge (5) are provided above said surfaces (100) and (101), andextend respectively longitudinally (x) and transversally (y) to thestructure (1). The carriage (6) supports a clamp (60) movable from andto the surfaces (100, 101) under control of a corresponding electricmotor or other equivalent actuator (MZ). The said clamp (60), as bestdescribed later, is intended to perform the following operations:

[0023] removing the reel-holders (3) from the surface (100) to disposethem onto the tanks (4);

[0024] removing the tanks-closing lids (40) to dispose them above thesame tanks (4) before introducing the programmed dyeing bath therein;

[0025] taking the reel-holders (3) out of the tanks (4) to place themwithin the spaces of the centrifuges or ovens and dispose them fromhere, or directly from the tanks, onto the parking surface (100).

[0026] In the example of FIGS. 1 and 2, the said surfaces (100) and(101) are cascade-arranged in the direction of the longitudinal axis (x)and the tanks (4) are disposed according to the vertexes of aquadrilateral. According to the example of FIGS. 3 and 4, instead, thesurfaces (100) and (101) of structure (1) are cascade-arranged in thedirection of the transverse axis (y), and the tanks (4) are lined up ina direction parallel to the longitudinal axis (x). In the latter case,it is possible to increase the production capacity of the machine (MT)by merely adding further modules (100′, 101′, 102′) cascade-likedisposed in the direction of longitudinal axis (x).

[0027] As illustrated in FIG. 5, each tank (4) of the machine (MT) ismade up of a substantially cylindrical vessel with vertical axis, whoseheight is such as to allow for a full introduction of one reel-holder(3). The bottom of the tank (4) shown in FIG. 5 is provided with aninlet duct (41) and an outlet duct (42) for the dyeing bath. Both ducts(41, 42) lead to a pump for the recirculation of the bath (43). Theinlet duct (41) is in correspondence of the reel-holder's axis (30); thesaid axis being hollow to allow the bath flowing from the inside of thereel to the outside and vice versa. The upper face of the tanks (4) isprovided with a ring nut (44) associated to a corresponding actuator(45) and intended to block the relevant lid (40) by interfering with theradial edges (400) of the latter. Each tank (4) is also advantageouslyprovided with an annular gasket (46) intended to result in facingrelationship with the lid (40) when the latter is disposed for closingor covering the tank.

[0028] As illustrated in FIGS. 7 and 8 of the attached drawings, eachlid (40) has a preset number (three, angularly spaced through 120°, inthe example) of radial edges or appendixes (400) intended to interactwith the ring nut (44) of each tank (4). Moreover, each lid (40) isprovided with an axial appendix (401) to be engaged, that is, graspedand respectively released, by the clamp (60) associated with saidcarriage (6). For example, the said appendix (401) is possibly made upof a central hub (410) solid to the upper side or face of lid (40) whicha circular flange parallel to same lid is associated with, that is,fixed to. On the opposite side, each lid (40) exhibits a central,internally hollow appendix (402) allowing same lid to be centered on theaxis of the reel-holder (3) disposed inside the tank (4).

[0029] With reference to the example illustrated in FIG. 9, wherein therectangles of dotted lines represent reels of various possible shapes,each reel-holder (3) comprises a central hollow axis or shaft (30) ontowhich a reel (2) is manually fitted, a lower tray (31) and an upper tray(32) which are intended for cooperatively clamping the reel (2) fromopposite sides, and a ring nut (33) for tightening the upper tray (32)onto the upper face of the reel (2). The upper tray (32) is suitablydrilled in the centre to allow the positioning thereof onto the axis(30) at a level corresponding to the height of reel (2). The lower trayis centrally provided with a seat (34) to receive the lower face of theaxis (30) and, on the opposite side, with a cup (35) allowing thecentering thereof within the intended tank (4): each tank (4) beingsuitably provided with a vertical, central appendix (not shown in thedrawings) in correspondence of the respective lower face. Screwed ontothe upper part of the shaft (30) is an appendix (301) whose shape andfunction correspond exactly to those of appendix (401) which the lids(401) are provided with. The jaws (600) of clamp (60) exhibit an innercavity (601) matching the profile of appendixes (301, 401) of thereel-holder (3) and lids (40). In order to load a reel-holder (3), anoperator fits a reel (2) onto the axis (30) until it rests fully on thelower tray (31), inserts the upper tray (32) on the same axis until itrests on the upper face of the reel (2) and tightens the ring nut (33),and then screws the gripping appendix (301) onto the upper end of theaxis (30).

[0030] The operation of the machine (MT) is as follows. Once thereel-holders (3)—being loaded by one or more operators as aboveindicated—have been disposed onto the surface (100) at the respectivepreset positions, the selected production program is started: thecarriage (6) moves on in correspondence of the reel-holder, according toprogram, the clamp (60) comes down to result at the level of therespective gripping appendix (301) and is activated, as illustrated inFIG. 10, to engage the latter and the reel-holder therewith; afterwards,the clamp (60) goes up and the carriage (6) performs the transfer of thereel-holder, thus held by the clamp (60), up to the tank (4) in which,according to program, the reel carried by the reel-holder will be dyed;at this moment, the clamp (60) comes down, thereby fully introducing thereel-holder into the said tank; subsequently, the clamp is deactivated,thereby releasing the reel-holder, and moved on until it results in tocorrespondence of the space in which the lids (40) are stacked; here theclamp is lowered and activated, as shown schematically in FIG. 11, toengage the first lid of the stack; afterwards the clamp (60) lifts up,with the lid (40) thus picked up, and the carriage (6) moves on the sameclamp in correspondence of the tank (4) wherein the reel-holder with thereel to be dyed has been previously disposed; here the clamp comes downby positioning the lid (40) onto the tank, then the same clamp isdeactivated and finally moved away with the carriage (6); following thedeactivation of the clamp (60), the actuator (45) of the same tankdrives into rotation the corresponding ring nut (44), thereby blockingthe lid (40); at this point, the dyeing bath (prepared, for example, asdescribed below) is introduced into the tank (4) and recirculated by thepump (43) for a programmed period of time; after this time is elapsed,the pump (43) is deactivated and the ring nut (44) is rotated inopposite direction by the same actuator (45) so as to release the lid(40); the latter is picked up by the clamp (60), likewise as previouslydescribed, moved into the lids-housing space and released; thereel-holder (3) is taken out from the tank (4) by the clamp (60)suitably moved on again to result in correspondence of the tank (4), anddisposed on the surface (100) of the structure (1), in the same startingposition or other programmed one, either directly or after a prolongeddwell within an oven or centrifuge (110), or other suitable system knownper se to those skilled in the art, for the removal of residual water.What has been above described being repeated cyclically throughout theprogrammed production process.

[0031] Moving the carriage (6) in the directions (x) and (y) ofstructure (1) is obtained by motors (MX) and respectively (MY), whichdrive into motion the bridge (5) along the guides (102) and the carriage(6) along the bridge (5), respectively. The lifting and lowering of theclamp (60) are operated by the motor (MZ). These three motors areassociated with a programmable central unit (UE) according to anoperational scheme such as the one illustrated in FIG. 21 known per seto those skilled in the art. The activation and, respectivelydeactivation of the clamp (60) are operated by an electromagneticactuator, not shown in the drawings, also associated with theprogrammable unit (UE). The latter is provided with a memory wherein thecoordinates of each reel-holder being on the parking surface (100) or onthe reel-treatment surface (101) are stored. Also stored in the saidmemory are the recirculation times for the baths within the tanks (4),as well as the coordinates of the same tanks, of the space for housingthe lids (40) and of the spaces for centrifugation/drying of the dyedreels.

[0032] The dyeing bath intended to feed the tanks (4) of the machine(MT) can be prepared in any suitable way, that is, by means of anysuitable machine or equipment. For example, a machine (MD) can be usedsuch as the one manufactured by the same applicant and available on themarket with the trademark “DOSORAMA WS”. This machine is described inthe document (IT) FI/2000/A153 to which reference may be made forfurther details. The said machine comprises, substantially, a stationarystructure (7) with a platform (70) upon which a plurality ofcontainers/dispensers (76) of solid products for preparing dyeing baths,and a plurality of bottle-like containers for solutions or liquidproducts, are placed at corresponding and preset positions. The saidplatform (7) has a transverse bridge (71) standing there above, movablealong two longitudinal guides (72) and having a mobile carriage (73)mounted thereon. Mounted on said carriage are means (74) able to pickup, move and operate the containers-dispensers of the solid products,and means (75) able to remove the liquid products out of the respectivebottles in order to inject them into the vessels which receive the solidproducts from the containers-dispensers. A description relating to oneway of using the machine (MD) is given later on.

[0033] Disposed between the machine (MD) and the machine (MT) is adissolution unit (D) which receives the liquid and solid products fromthe machine (MD), provides for the dissolution thereof and launch them,that is, delivers them to the tanks (4) of the machine (MT).

[0034] With reference to the example of FIGS. 16-18, the saiddissolution unit comprises a stationary structure (8) upon which ahorizontal table or platform (80) is placed. The latter is associatedwith a rotary actuator allowing it to rotate about its central axis (82)and thereby allowing the positioning of a vessel (83) resting thereon,between a station (A) for receiving the products to be dissolved to formthe dyeing bath, and a station (B) wherein the very dissolution takesplace. The dissolution means comprise a mixer (84) solid to a verticalhollow shaft (85) which is associated with a corresponding electricmotor (850) via a belt drive (851). The shaft (85) and mixer (84) areprotected by a cylindrical fixed screen (88) anchored to said structure(8) and, in correspondence of its upper face has a sealing gasket (880)and a port for the hollow shaft (85) to go through. When the vessel (83)at station (B) is lifted up (in a manner to be described later on) untilits edge is against the upper face of the screen (88), a sealed chamberis formed, for the dissolution of the products, which is limited belowand laterally by the vessel (83) and above by the upper face of thescreen (88). The shaft (85) is connected to a fixed conduit (852) by arotary joint (853). Beside, above the screen (88), a chamber (89) isprovided associated with a compressor (890). The latter makes itpossible to pressurize the said chamber (89) and to launch the productsdissolved therein via the shaft (85) and conduit (852). The latter, ascan be seen in FIGS. 12 and 13, is connected to the pump (43) of eachtank (4) via corresponding ducts (800) by-passed via three-way solenoidvalves (801) associated with the central unit (UE).

[0035] Disposed in correspondence of station (A) below table (80) is anelectronic scale (86) to weigh the quantity of solid products graduallyintroduced into the vessel (83). The said scale (86) is mounted on asupport associated with an actuator cylinder having vertical axis (860).Disposed in correspondence of station (B) below platform (80) is anactuator cylinder with vertical axis (87) allowing the vessel to bedisposed in lifted position for the dissolution of the products beingput therein and, vice versa, be re-positioned on platform (80) uponcompletion of the dissolution and launch steps. The motor (850), scale(86, compressor (890) and actuators (87) and (860) are all associated tothe central unit (UE) for their programmed operation. The bottom (830)of vessel (83) is loosely positioned in a corresponding seat (880) ofplatform (80) so that the lower face of the vessel (83) will resultsimply supported on the platform and able to be lifted from the pan ofthe scale (86) to the station (A) and from the cylinder (87) to thestation (B) of the dissolution unit. The drawing of FIG. 17B showsactually this constructional detail.

[0036] One possible operating cycle of preparation and launch of adyeing bath according to the invention is as follows. The carriage (73)places the means (74) in correspondence of the container-dispenser (76)holding the necessary solid product, the same means (74) pick up thecontainer-dispenser and place it in the station (A) of the dissolution(D), in correspondence of the vessel (83) which rests onto the table(80) above the scale (86), as illustrated in FIG. 19-I. At this point,the scale (86) is lifted by the actuator (860), so that the weight ofthe vessel (83) will weigh fully onto the scale pan (FIG. 19-II), afterwhich the means (74) operate the dispenser (76) to introduce theprogrammed quantity of solid product into the vessel (83), asillustrated in FIG. 19-III. Afterwards, the means (74) move away fromstation (A), as illustrated in FIG. 19-IV, and their place is taken bythe means (75) provided for the delivery of liquid products, asnecessary for the completion of the selected formula (FIG. 10-IV).Thereafter, the means (75) are activated for delivering the programmedquantity of liquid into the vessel below (83), as illustrated in FIG.19-IV, then the means (75) drive the carriage (73) away and the scale(86) is lowered (FIG. 19-VII, 19-VIII e 20-I), so that at end of thisstep the vessel (83) holding the ingredients of the required bath willresult again resting onto the platform (80), as shown in detail in FIG.17B. Following this, the platform (80) is rotated through 180° about theaxis (82) by the actuator (81), so that the vessel (83) moves on toresult in correspondence of station (B) of dissolution unit (FIG.20-II). At this point, the actuator (87) lifts up the vessel (83) untilthe edge of the latter is in contact with the upper face of the screen(88), as illustrated in FIG. 20-III. Then the motor (850) is started, asshown in FIG. 20-IV, and the dissolution of solid products into liquidproducts, that is, the formation of the programmed dyeing bath takesplace with the addition of programmed amounts of hot and cold waterbeing fed through a corresponding feed pipe (855), which is shownschematically only in FIG. 20-IV for the sake of simplicity. After apreset time, the motor (850) is deactivated (FIG. 20-V) and the bathflows through the duct (852) (FIG. 20-VI) owing to the pressurization ofthe dissolution chamber (FIG. 20-VII), while possibly keeping the shaft(85) in rotation (FIG. 20 VIII). Upon completion of this step, duringwhich the dyeing bath is introduced into the tank (4) programmed by themachine (MT) as previously described, the motor (850) is switched off,the vessel (83) is moved back onto the underlying platform (80) (FIG.20-IX) and the latter is again rotated through 180° about the axis (82)to dispose the vessel (83) at the initial position (FIG. 20-X) ready toreceive other products for the preparation of a further dyeing bath.

1. Machine for dyeing textile materials, characterized in that itcomprises a stationary structure (1) with a surface (100) for supportingor parking the materials already treated or to be treated, saidmaterials being disposed upon said surface at correspondingpredetermined positions, in that it comprises a surface (101) with aplurality of tanks (4) to be fed with a dyeing bath, and in that itcomprises means (60) for removing and handling the materials betweensaid supporting or parking surface (100) and said tanks (4), the saidmeans (60) being associated with a programmable unit (UE).
 2. Machineaccording to claim 1, characterized in that said materials are reels ofyarns (2) fitted onto corresponding reel-holders (3).
 3. Machineaccording to claim 1, characterized in that a substantially cylindricalcontainer is associated with the surface (100) of the tanks (4) and hasmore lids (40) fitted into its vertical axis for closing sealingly thetanks (4).
 4. Machine according to claim 1, characterized in that atleast a space (110) is associated with the surface (110) of the tanks(4) for housing a residual water extraction device or a drying oven. 5.Machine according to claim 1, characterized in that the said structure(1) has two upper longitudinal guides (102) with a bridge (5) driveninto a sliding movement there along by a corresponding electric motor(MX), said bridge (5) making up a guiding element for a carriage (6)associated with an electric motor (MY) allowing the movement thereofalong the same bridge, the carriage (6) supporting said means (60) for amovement from and to the surfaces (100, 101) under control of acorresponding electric motor or other equivalent actuator (MZ). 6.Machine according to claims 1 and 5, characterized in that the saidmeans (60) consist of a clamp.
 7. Machine according to one or morepreceding claims, characterized in that the said means (60) provide forcarrying out the following operations: removing the reel-holders (3)from the surface (100) to dispose them onto the tanks (4); removing thetanks-closing lids (40) to dispose them above the same tanks (4) beforeintroducing the programmed dyeing bath therein; removing thereel-holders (3) out of the tanks (4) to dispose them within the spacesof the centrifuges or ovens and dispose them from here, or directly fromthe tanks, onto the parking surface (100).
 8. Machine according to claim1, characterized in that the said surfaces (100) and (101) arecascade-arranged in the direction of the longitudinal axis (x), and thetanks (4) are disposed according to the vertexes of a quadrilateral. 9.Machine according to claim 1, characterized in that the said surfaces(100) and (101) are cascade-arranged in the direction of the transverseaxis (y), and the tanks (4) are lined up in a direction parallel to thelongitudinal axis (x).
 10. Machine according to one or more precedingclaims, characterized in that each of said tanks (4) is associated witha corresponding pump (43) for the recirculation of the dyeing bath. 11.Machine according to claim 1, characterized in that the upper face ofthe tanks (4) is provided with a ring nut (44) associated with acorresponding actuator (45) and intended to block the relevant lid (40)after introduction therein of the material to be treated.
 12. Machineaccording to claims 1 and 3, characterized in that each lid (40) has apreset number of radial edges or appendixes (400).
 13. Machine accordingto claim 12, characterized in that the said radial edges (400) of lids(40) are in number of three, angularly spaced through 120°.
 14. Machineaccording to claims 1 and 3, characterized in that each lid (40) isprovided, in correspondence of its upper side or face, with a grippingappendix (401) intended to be engaged with, and respectively disengagedfrom said means (60).
 15. Machine according to claims 1 and 3,characterized in that each lid (40) is provided, in correspondence ofits lower side or face, with a central hollow appendix (402). 16.Machine according to claims 1 and 2, characterized each reel-holder (3)comprises a central hollow axis or shaft (30) onto which a reel (2) ismanually fitted, a lower tray (31) and an upper tray (32) which areintended for cooperatively clamping the reel (2) from opposite sides,and a ring nut (33) for tightening the upper tray (32) onto the upperface of the reel (2): the upper tray (32) being suitably drilled in thecentre to allow the positioning thereof onto the axis (30) at a levelcorresponding to the height of reel (2), the lower tray is centrallyprovided with a seat (34) to receive the lower face of the axis (30)and, on the opposite side, with a cup (35) allowing the centeringthereof within the selected tank (4), each tank (4) being provided witha vertical, central appendix in correspondence of the respective lowerface.
 17. Machine according to claim 16, characterized in that on theupper part of the shaft (30) an appendix (301) is provided intended forengagement with, and respectively release from said means (60). 18.Plant for dyeing textile materials, characterized in that it comprises amachine (MT) according to one or more preceding claims, a machine (MD)for feeding the materials necessary for the preparation of a dyeingbath, and a dissolution unit (D) located between said machines, the saiddissolution unit (D) being provided with means for receiving anddissolving solid and/or liquid products with which the said bath isobtained.
 19. Plant according to claim 18, characterized in that thesaid dissolution unit comprises a stationary structure (8) upon which ahorizontal table or platform (80) is placed, the latter being associatedwith a rotary actuator allowing it to rotate about its central axis (82)and thereby allowing the positioning of a vessel (83) resting thereon,between a station (A) for receiving the products to be dissolved to formthe dyeing bath, and a station (B) wherein the very dissolution takesplace.
 20. Plant according to claim 18, characterized in that the saiddissolution means comprise a mixer (84) solid to a vertical hollow shaft(85) which is associated with a corresponding electric motor (850) via abelt drive (851), the shaft (85) and mixer (84) being protected by acylindrical stationary screen (88) which is fixed to said structure (8)and, in correspondence of its upper face has a sealing gasket (880) anda port for the hollow shaft (85) to go through.
 21. Plant according toclaims 18-20, characterized in that the said vessel (83) and said screen(88) cooperate to delimit a sealed dissolution chamber, delimited belowand laterally by the vessel (83) and above by the upper face of thescreen (88).
 22. Plant according to claims 18-20, characterized in thatthe said shaft (85) is connected to a fixed conduit (852) via a rotaryjoint (853).
 23. Plant according to claim 18, characterized in that saiddissolution unit can be pressurized.
 24. Plant according to claim 18,characterized in that said dissolution unit (D) is connected to the pump(43) of each tank (4) via corresponding ducts (800) by-passed viathree-way solenoid valves (801) associated with the central unit (UE).25. Plant according to claims 18 and 19, characterized in that incorrespondence of station (A), below table (80), an electronic scale(86) is disposed to weigh the quantity of solid products graduallyintroduced into the vessel (83), the said scale (86) being mounted on asupport associated with an actuator cylinder having vertical axis (860).26. Plant according to claims 18 and 19, characterized in that incorrespondence of station (B) below platform (80) an actuator cylinderwith vertical axis (87) is disposed allowing the vessel to be disposedin lifted position for the dissolution of the products being put thereinand, vice versa, be re-positioned onto platform (80) upon completion ofthe dissolution and launch steps.